They are constructed out of .75" particle board with a 1.5" front baffle. I decided not to go with MDF because I really can't stand the ultra fine dust it produces when you combine it with a router.  The internal volume is 1.25 ft^3 all internal sides are lined with 3" thick R-12 insulation (the yellow stuff).  The port is 2 7/8" diameter and 2 1/4" long yielding a f3 point of about 52hz.  The internal brace runs vertically about midway in the cabinet with large holes cut through it. 

The front edges are .5" x .5" red oak quarter round stock and the rest of the finish is red oak veneer.  The finish is 5 coats of Watco Danish Oil in the natural finish.  My original plan was to coat them in some high gloss poly, but I didn't want to risk screwing it up so I stopped at the oil.

This is what happens to a tweeter when its been bounced off a concrete floor.  (Hint - they don't bounce well at all)

Darren K from Parts Express was doing a similar project with the same drivers and was kind enough post the frequency & impedance data files that he measured.  Thanks again Darren!

After numerous models on the computer and hours of listening this is my final crossover (for now anyway).  They image absolutely fantastic.  Bass is decent but not earth shaking, it has a nice 'punch' to the sound but does not really dig very low, kinda expected from drivers with such a stiff spider - on the up side I doubt you would ever bottom them out!  Mids and highs are another story, they have a somewhat 'bright' sound to them but I don't believe it to be a bad thing, it doesn't induce any listening fatigue or have a sound that can shatter your teeth.

Crossover occurs at 3.2khz with 3 order electro-acoustical slopes both the woofer and tweeter.  The parallel resonance circuit was put there to flatten out a large bump in the woofer response starting at about 5k, by eliminating it I was hoping to balance out the upper and lower midrange response and give it more of a robust sound, especially with male vocals.  It didn't.  What it did do was drastically change the imaging, for the better!  As I said, I have lots of learning and experimentation to do.
 

Woofer Crossover.  The caps are 100v electrolytic and the .68mh coil is a 14ga air core and the .16mh coil is a 20ga air core.  Both resistors are the non inductive type.

Tweeter Crossover.  All tweeter caps are 250v Solen fast caps and the coil is a 20ga air core.  The resister is non inductive.  Note the normal polarity connection.

Here is a shot of the predicted response:

 
 

Crossover Update - May 20/05

I swapped out the peerless tweeters with some Audax TM025F1 textile dome tweeters. I was not happy with the high crossover point of the current design. After some more design work, this is the result:

Tweeter

Lowpass